CNC grinder helps start a business

With the economy beginning to head south, many manufacturers were searching for ways to cut costs during the late 1990s. To many, this would seem to be an inopportune time to start a niche grinding business. However, viewing the proverbial glass as being half full, Joe Scolaro saw this period as a window of opportunity.

At the time, Mr. Scolaro was a manufacturing department supervisor at a Cleveland plant, and he felt he'd "hit the ceiling" as far as potential for career advancement. He met a machinery dealer who had a used manual Studer from United Grinding (Miamisburg, Ohio) on his floor. Mr. Scolaro bought it, leased a 2,500 square-foot space, and, along with partner Dale Stebner, began knocking on doors. Thus began Venture Grinding, Inc. (Cleveland, Ohio).

Since that first used manual Studer 6 years ago, Mr. Scolaro and Mr. Stebner have bought three others--an S21, an S36 and the latest model, the S31 with a full B axis, which permits combining several operations in one chucking.

Adv

Mr. Scolaro says he started Venture Grinding to fill a niche. "Most machine shops don't have a grinding department," he says. "They do extensive turning and milling, but when it comes to grinding, most send the job out, primarily because grinding is a specific and highly variable discipline. Hardness, grit size, makeup, the dressing method and coolant are among the many aspects to be considered.

"You can teach programming relatively easily, but in a grinding operation, you must take your eyes and ears out on the floor," he continues. "Listening and feeling for vibration can indicate how a part is running. For instance, the operator can ascertain if the wheel is too hard, if the part is getting too warm or if the coolant concentration needs to be modified.

"I don't want to call grinding an art form, but there's certainly more involved in finishing a ground part than in turning or milling a part," Mr. Scolaro adds.

According to Mr. Scolaro, the last 4 years have been rough. A lot of shops Venture Grinding's size and larger have not survived. The companies that have remained, the OEMs and the bigger machine shops, have had to make every possible effort to reduce costs.

"I knew someone was still going to be making small lots of complex parts, and we stepped up our sales efforts and won jobs," Mr. Scolaro says. "Being a startup, leasing shop space, having the best machines and having low overhead, we were able to give customers a more competitive price. Sometimes we were offering same-day turnaround to get the business. That's something that companies who went overseas with their parts gave up--quick response."

One of the many factors Venture Grinding attributes to its success is the communication between the company and its customers. Mr. Scolaro explains that, in most cases, grinding is the last in a series of several operations. For instance, many jobs the company receives are from heat-treating operations. If the upstream processes fall behind in schedule, it's difficult for the company to make up the difference.

"We try to maintain a schedule, while still being flexible," Mr. Scolaro says. "If we get an order with a few days notice, it's not a problem. Because of the flexibility and reliability of the Studer machines, we can run jobs as small as two pieces to lots comprised of as many as 10,000 pieces." The Studer pictogramming and the quick-set programming feature makes rotating the B axis; maintaining the relationship between the wheels and the part; and change-over, setup and training relatively easy.

Another strategic tip Mr. Scolaro offers is the 20 percent rule. He says he tries to never have more than 20 percent of his work tied to one customer; in fact, 20 percent makes him nervous. It's not that the company turns away large orders, but it continues to look for new customers so that it is never in a position where there will be serious problems if a customer sends work overseas.

Currently, Mr. Scolaro says the company has about 16 or 17 percent of its work tied to one customer. However, he notes that taking this percentage rule too far in the other direction--for example, having less than 4 percent or 5 percent tied to each--would be unfeasible. "It would be impossible to keep track of who was doing what for whom and when, which would make scheduling problematic," explains Mr. Scolaro.

Verify CNC program correctness

All CNC programs must be verified. While new programs present more challenges than proven programs, operators must be careful and alert during every step of a program's verification.

Step 1: Verify the correctness of the CNC program. This step is required for new programs or for programs that have been modified since the last time they were run (possibly because of engineering changes). It is also necessary to do this step if there is any doubt as to whether you are working with the current version of the program (after making changes at the machine the last time the job was run, perhaps the setup person forgot to save the program).

The objective of Step 1 is solely to confirm the correctness of motions commanded in the program. Other potential problems will require further verification at the machine; however, when Step 1 is successfully completed, the setup person will have confidence in the motions made by the program.

Some operators perform this step on the CNC machine during setup, which requires time. Many current model CNC machine tools have built-in toolpath displays, and as long as you verify the new program while the machine is running, you won't interfere with production. Not all CNC machines allow you to view one program's toolpath while another program is running. In this case, Step 1 will add to the setup time. If mistakes are found, the time it takes to correct them will also add to setup time.

Not all CNC machines provide toolpath display, and it is difficult to see a program's true motions by watching a CNC machine run a program. You may not be able to achieve the objective of Step 1 in this case because there might be serious mistakes to be found and corrected in Steps 2 and 3.

With the affordable off-line G-code level toolpath verification systems available, Step 1 can be performed for upcoming jobs, while the machine is running production shortly after a CNC program is created or modified. With these desktop computer-based systems, users can gain a better view of the program's movements than they could by watching the machine move.

If using an off-line system, the programmer is usually responsible for this step. They will perform this step shortly after the program is created. While most CAM systems have toolpath verification that is done as the CNC program is created, if changes are made to the G-code level program, many CAM systems cannot display the changes.

Even if changes are not made to the G-code level program, I recommend using a G-code level off-line program verification system to check the program's motions. If nothing else, this gives the programmer another way to see the motions a program is going to make before it is run on the CNC machine.

It takes a watchful eye to catch mistakes with an off-line system. Because the job is not currently on the machine, there is no real urgency, so mistakes can slip by. It might help to have someone else perform this step (another programmer or a setup person). Because the original programmer is so familiar with the job, he or she might not catch obvious mistakes. A setup person can be the best bet, since he or she will be responsible for actually running the program at the machine.

Many off-line systems don't show the location of clamps and other obstructions, so the person verifying the program must be able to visualize the placement of workholding components around the workpiece. The more problems they catch, the fewer problems there will be for the setup person to find and correct.

There may still be problems with the program's motions alter Step 1 is completed, but these problems should not be severe. Even with a toolpath display, it can be difficult to catch small motion mistakes. Some solid model-type program verification systems allow performing measurements on the virtual workpiece machined in the system; however, you must suspect that a problem exists before taking a measurement. For instance, with a mistake of less than 0.01 inch, it is likely that you may not suspect that anything is wrong.

Software aids in wheel design for CNC tools and grinders

Suited for X Class range of CNC tools and cutter grinders, Wheel Editor v27 includes key hole punch software for creation of punch geometries from library of shapes. Software also enables creation of customized contours and punches with concave and convex shapes. Additional features include Delta-C R850 drill point sharpening function and Profile Pivot Editor function to optimize feedrate.

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Melbourne - ANCA has recently released version 27 for their X Class range of CNC Tools and Cutter Grinders. This version is packed with new innovative features that make the performance of an ANCA machine more efficient, provide significantly extended flexibility and enhance the possible spectrum of applications. The two main new features with version 27 are the addition of Key Hole Punch software and Delta-C R850 Drill Point. This increases the applications on version 27 to more industries. The Keyhole Punch software allows creation of punch geometries from a library of shapes and also allows creation of customised contours. Unlike standard punch grinders this solution is able to create punches with concave and convex shapes. Once the shape is designed the software will specify the wheel shape required to grind the punch. This wheel shape can then be loaded into the ANCA Wheel Editor. The Delta-C R850 drill point has been implemented in iGrind and is available in the drill wizard. This is a proprietary drill shape. Version 27 enables sharpening of this drill shape under license.

Version 27 has a wide range of applications, which enable users from many different industries to utilise its broad and flexible functionalities. Some of the more common applications which have been improved are:

Profile

Profile Pivot Editor function is a new feature of profile software. This option changes the way in which nine o'clock grinding positions the wheel. If full control is selected then the pivot angle can be specified at the start and end of each profile element. An option has been added in profile grinding that allows the feedrate to be optimised to maintain a constat passage of the grinding point across the profile.

Step

The wizard has been added to the Step editor operation that will allow a single DXF file to be split into multiple step sections. A new menu has been added to the Step Editor operation that allows geometry to be displayed and selected in iView.